Apparatus for producing allot



Dec. 5, 1950 R. K. HPKlNs 2,532,914

APPARATUS FOR PRODUCING ALLOY INGOTS Filed July 14. 1949 Y 2sheets-sheet 1 VENTOA ROBERT HOPKINS ATTORNEY M w m 2 mm m 9 t TW 0 2,MH 3 a V 5, .r MK. YT .A 2 t m E m w u O d. Il R R. K. HOPKINS APPARATUSFOR PRODUCING ALLOY NGOTS Dec. 5, 1950 Filed July 14, 1949 Patented Dec.5, 1950 APPARATUS FOR PRODUCING ALLO INGOTS Robert Ki Hopkins, StatenIsland, N. Y., assigner to The M. W. Kellogg Company, Jersey City, N.J., a corporation of Delaware Application July, 14, 1949, Serial No.104,774

8 Claims.

The present invention relates to the art of producing metals by thefusing action of ilux submerged electric current discharges.

Metal can be produced by dipping a plurality of metal wires or rodscontaining base ingredients of the metal to be produced into a body ofiiux and employing said wires as consumable electrodes to dischargeelectric current therefrom beneath the surface -of said flux. Thisresults in the generation of suiilcient heat to melt progressively thewires and in the deposition of the molten metal as it is produced,beneath the surface of the flux and into a mold, where it will beprogressively solidified and cast intol an ingot or body of the desiredshape and analysis.

As the electrode wires are consumed, they must be continuously fedendwise towards the fusing zone beneath the surface of the flux tomaintain continuous current discharge of the desired characteristics. Atthe same time, the receptacle or mold in which the fused metal isdeposited must be moved relative to the wires, to compensate for theprogressive increase in the depth of the deposited metal.

The electrode wires are of different composition according to themake-up of the metal to be produced, and these must be fed at relativerates into the fusing zone, according to the desired quantitive analysisof said metal.

One object of the present invention is to provide a new and improvedapparatus for progressively producing metals of desired analysis by thefusing action of flux submerged electric current discharges uponconsumable electrodes containing the base ingredients of the metals tobe produced.

Another object is to provide an apparatus of the character described forfeeding multiple electrodes at predetermined relative rates into thefusing zone asi they are consumed, and for maintaining automaticallysaid relative feed rates, regardless of the rate of production of themetal.

A further object is to provide an apparatus of the character described,having means by which the relative rates of feeding of the multipleelectrode wires may be selectively adjusted.

In carrying out certain features of the present invention, asingle'motor is provided for feeding all of the consumable electrodes inthe form of wires or rods at predetermined relative rates towards thefusing zone beneath the surface of the flux. For that purpose, there areprovided in the drives between the single motor and the electrode wires,transmissions having their speed ratios related according to therelative rates of feed of the wires desired. These relative rates offeed depend on the desired analysis of the metal to be produced and aremaintained substantially constant regardless of the speed of the drivemotor.

A As an additional feature, the drive motor is automatically controlledin accordance with the desired feed rate of at leastone of the electrodewires, while the relative feed rates of the wires are maintainedsubstantially constant. This desired feed rate is automaticallycontrolled from a characteristic of the current discharge, such asvoltage, to maintain this characteristic substantially constant. Thisvcontrol, in turn, regulates the rate of production of the metal.

As an additional feature, the transmissions in the drives between thedrive motor and some of the electrode wires are constructed and arrangedto permit them to be changed and the relative speed ratios of the drivesto be varied thereby, according to the relative feed ratios of saidwires desired.

Various other objects, features and advantages of the present inventionare apparent from the following description and from the accompanyingdrawings. in which:

Fig. 1 is a diagrammatic view partly in vertical section and partly infront elevation of an apparatus embodying the present invention;

Fig. 2 is a section of the apparatus taken approximately along the lines2-2 of Fig. l;

Fig. 3 is a top plan view of a portion of the apparatus, and showsparticularly the transmission to one of the wires in the set-up in Figs.1 and 2 replaced by a transmission with a difierent speed ratio:

Fig. 4 is a side elevation of the transmission mounting oi' Fig. 3, butshowing in dot and dash lines the positions assumed by twointerchangeable transmissions of different speed ratios:

Fig. 5 is a detail section taken on the lines 5 5 of Fig. 3, but on anenlarged scale; and

Fig. 6 is a detail section taken on lines 8--0 of Fig. 1, but on anenlarged scale.

Referring to the drawings, the apparatus of the present inventionprogressively produces metal of the desired analysis in a mold I0, in amanner to be described, and deposits this metal as it is produced undera protective layer il of molten flux and in said mold, where itprogressively solidiiles into the desired shape. The mold i0 may be ofany suitable design, and in the specific form shown, it has the shape ofan upright cylinder for casting ingots. The mold lil may be of suitablematerial, such as refractory material or metal and in the form shown, itis of copper and has a jacket 1 with inlet 3 and outlet 9 to permitcirculation of a cooling medium, such as water, in heat exchangerelationship with its internal walls.

The metal is produced in the mold I by the fusing action of electriccurrent discharges from consumable electrodes, shown in the form ofslender rods or wires I2, I3 and I4, three being shown for the purposeof illustration, but any number more than one being contemplated,according to the desired composition of the metal to be produced. Eachof these wires contains some of the base metal and other ingredientsrequired i'or the metal to be produced. The compositions of the wiresI2, I3 and I4 are desirably different, althoughj it is conceivable inaccordance with the present invention, to have two or more wires of thesame composition, especially where the metal to be produced requirescomparatively large amounts of ingredients contained in thiscomposition.

The electrode wires I2, I3 and I4 are supplied from respective spools orreels I5 supported for free rotation on the superstructure I6 of a frameI1 and extend through respective guide and current contactor tubes I9.The contactor guide tubes I9 are desirably arranged in the mold I0 equaldistances apart, and are supported therein I in any suitable manner (notshown). To prevent their rapid destruction by the intense heat developedin the mold I0, the tubes I9 have respective jackets with inlets 2I andoutlets 22 for circulation of a cooling medium such as water.

'I'he lower ends of the contactor guide tubes I9 are desirably curvedinwardly to bring the electrode wires I2, I3 and I4 close together inthe flux II within a concentrated heating zone and to assure goodelectrical contact between the wires and their respective tubes I9adjacent the lower ends thereof. The lower ends of the electrode wiresI2, I3 and I4 dip into the iiux II and produce current dischargesbeneath the surface thereof across the gaps separating said wires fromthe metal 24 which is produced from the fusion of these wires in theregion of said gaps and which is deposited in the mold I0 beneath thesurface of said flux.

The flux layer II protects the deposited metal 24 against atmosphericcontamination, prevents rapid dissipation of heat from said metal duringits solidication, and absorbs or floats out as slag the impurities inthe metal. The flux II for that purpose may be of any suitablecomposition having the necessary metallurgical and chemical.

properties for carrying out the process, and may for that purposecomprise some suitable form of silicate.

The electric power for creating the necessary electric currentdischarges is derived from generators 30, 3| and 32, which desirablycorrespond in number to the number of electrode Wires I2, I3 and I4employed, and each of which may constitute part of a motor-generatorset. One side of all of these generators is electrically connected orgrounded to the mold l0 by a line 33, while the other side of eachgenerator is connected by a line 34 to a respective contacter guide tubeI9 for conduction of current to the corresponding electrode wires I2, I3and I 4.

The generators are preferably D. C. as with D. C. the metal producingoperation is more stable, but, in accordance with certain aspects of theinvention, the generators may be A. C.

As the electrode wires I2, I3 and I4 are continuously fused and consumedin'the flux II, it is necessary to continuously feed these wiresendwise, depending on the rate of their consumption, to maintain thecurrent discharges from the ends of said wires substantially constant involtage or other electrical characteristics. For that purpose, there isprovided on the frame I1 above the mold I0 a platform 40 supportingthevwire feed mechanism embodying the present invention. The wire feedmechanism comprises a single drive motor 4I, supported at one end of theplatform 40 substantially midway between the sides thereof, directlydriving a shaft 42 supported in bearings, including a bearing 43. Thedriving shaft 42 drives the wire feed device 44 for the electrode wireI2 through a speed reduction gearing 45, shown comprising a worm 45 onsaid shaft 42 meshing with a worm wheel 41 on a shaft 45 which issupported in bearings on the platform 40 and which extends crosswise ofsaid platform. Connected to the worm wheel 41 for rot-ation therewith onone side of the electrode wire I2 and constiuting part of the wire feeddevice 44 is a wire feed roller 5I having a peripheral groove forconformably receiving in feed engagement, the electrode wire I2. On theother side of the electrode wire I2, in peripheral engagement therewithand constituting another part of the wire feed device 44, is aspring-pressed idler roller 52. The wire feed device 44 for the wire I2is similar to the feed device 44x for the electrode wire I3, shown inFig, 6. and its details will be made apparent from the descriptionhereinafter of said feed device 44a.

With the arrangement so far described. the electrode wire I2 is fedcontinuously towards the flux submerged fusing zone in accordance withthe speed of the drive motor 4I. To feed the other electrode wires I3and I4 from the drive motor 4I, but at predetermined rates relative tothe feed rate of the electrode wire I2, there is provided a pair ofcountershafts and 56 on opposite sides of the drive shaft 42, eachjournalled in bearings 51 and 58 and each connected atone end to the`input member of the correspending wire feed device 44a or 44b for theelectrode wires I3 and I4 respectively. Between the shaft 42 and thecountershaft 55 is a transmission comprising a gear on said shaft 42,meshing with a gear 6I on a stub shaft 62 journalled in a bearingbracket 83B mounted adjustably on the platform 40, for the purpose to bemade apparent. The stub shaft 62 drives the countershaft 55 through aconnection 64B, which is of the universal type, for the purpose to bedescribed.

The speed with which the electrode wire I3 is fed depends, therefore, onthe speed ratio of the gear transmission 60, 6 I.

In a similar manner, the countershaft 56 for the feed device 44h isdriven from the drive shaft 42 by a transmission, comprising a gear BIDon a stub shaft 62h, meshing with'the gear 50 on the drive shaft 42 andjournalled in a bearing bracket 63b mounted adjustably. on the platform40. The stub shaft B2b drives the countershaft 56 through a universalconnection 64b.

The speed with which the electrode wire I4 is fed depends, therefore, onthe speed ratio of the gear transmission B0, 6 I".

The feed device 44l for the electrode wire I3 is driven from thecountershaft 55 through a speed reduction gearing, comprising a worm 46"on said shaft, meshing with a worm wheel 41 on an overhanging shaft 48which is supported 8 in bearing 50* on the platform Il and which extendscrosswise of said platform. The worm ably receiving in feed engagementthe electrode wire I3. The worm wheel l1* hasthe wire feed roller 5Iaconnected thereto, as for example, by bolt and is insulated therefrom bymeans of an intervening disc 1I and bolt bushings 12 of\ non-conductingmaterial.

The wire feed device u* comprises on the other side of the wire I3, anidler roller 52 `having a cylindrical periphery in engagement with saidwire and supported on a stub shaft or arbor 13. For yieldably pressingthe idler roller 52l against the wire I3, the stub shaft 13 is carriedon a yoke or fork 14 at one end of a plunger 15, insulated from saididler roller by a bushing 15 of non-conducting material and telescopinginto tube 11 (Figs. 1 and 2) rigidly affixed to a cross frame piece 18at one end of the platform 40. A spring 80, bearing at one end against acollar 8| rigid with the plunger 15, and bearing at the other endagainst a plunger embracing collar 82 secured to one end of the tube 11,urges the idler roller 52n yiedably against the wire I3 to press saidwire into feed engagement with the drive feed roller 5I.

The feed device Mb for the wire Il is similar to the feed device a forthe wire I3 already described, sorne parts of said feed device b beingindicated in the drawings with numerals which are the same as those ofthe corresponding parts of the feed device 44, but which distinguishtherefrom by the subindex letter b. The feed device Mb is driven fromthe countershaft 5E through a speed reduction gearing comprising a worm46h and worm wheel 11b as in the case of the feed devices 44 and M.

The feed rates for the wires I3 and I4 with respect to the feed rate ofthe wire I2 may be changed by changing the gear 6In or 6I. Since anychanges in the size of the gears 6I'L and 6Ib moves the axes of thesegears transversely of the main drive. shaft (I2, it is necessary toprovide adjustable means for supporting these gears in mesh with thegear 68. For that purpose, the bearing brackets 63a and 63 for theshafts of these gears are adiustably mounted. In the case of the bearingbracket 63e. this bracket is supported on one of the horizontal sideframe pieces 85 (Figs. 3 and 4) of the platform 48 through a block 88,which is shown of hollow construction and of rectangular cross-sectionand which is rigidly secured to said frame piece. The bearing bracket 63has one end adjustably secured to this block bv means of bolts 81passing through elongated slots 88 in said bracket and accessible forloosening or tightening action through the open ends of said block. Byloosening the bolts 81, the bearing bracket 63a may be moved crosswiseof the platform to bring the new gear IiIa thereon into proper mesh withthe drive gear 60. This adjustment of the bearing bracket moves the stubshaft 62'l carrying the gear 6Il transversely with respect to thecountershaft 55, and may bring this stub shaft out of axial alignmentwith said countershaft. To maintain a drive between the two shafts and62* irrespec tive of the relative positions of their axes, theconnection 64a is a universal one of any suitable type. In the specificform shown, this connection comprises a connecting piece 30 with auniversal swivel end attachment to the adjacent end of the countershaft55 and with a universal swivel end attachment to the adjacent end of thestub shaft 62l effected through an intervening forked sleeve 9|embracing said stub shaft .and keyed thereto (Fig. 5) in a manner topermit said shaft to be released from said sleeve when it is desired tochange the gear 8 I.

In Fig. 2, the gear 6I* is shown of such size, that the axis thereof isin alignment with the countershaft 55. In Figs. 3 and 4, the position ofthe bearing bracket 63", corresponding to the set-up of Fig. 2, is shownin dot and dash lines. In Fig. 3, the position of the new gear 8 I*replacing the smaller gear 6In of Fig. 2, to reduce the speed of feed ofthe wire I3 with respect to the speed of feed of the wire I2, is shownin full lines and in Figs. 3 and 4 the corresponding adjusted positionof the bearing bracket 83* is shown in full lines. This adjusted set-upthrows the stub shaft (i2n and the countershaft 55 out of axialalignment as shown, but the universal connection |54EL accommodatesitself angularly to this shaft misalignment. The slide key fit betweenthe sleeve 8| and the stub shaft 62EL permits this sleeve to accommodateitself axially according to the angularity of the connection 64B.'

The bearing bracket 63b and the universal connection 64b associated withthe feed for the electrode wire I4, are similar to the bearing bracket63, and the universal connection 84* respectively associated with thefeed for the electrode wire I3 already described.

As the metal is produced and deposited in the mold III, the level of themetal rises therein.

Suitable means are provided for moving the mold I0 continuouslydownwardly with respect to electrode wires I2, I3 and I4 and at uniformspeed, depending on the rate of metal production in said mold, tomaintain the positional relationship between the surface of thedeposited metal and the discharge ends of said electrode wiressubstantially constant. In the specic form shown, this mold moving meanscomprises a platform 93 (Fig. l), on which the mold I8 is supported,connected to an upright feed screw 3l. A motor (not shown) moves thefeed screw l axially through a drive, comprising a worm (not shown)meshing with a worm wheel 95 threaded on said feed screw and heldagainst axial movement in any suitable manner, so that upon rotation ofsaid worm wheel, the feed screw is moved axially to cause correspondingmovement of the mold. As an alternative the mold III can be heldstationary and platform 40 raised as the level of the metal in mold I0rises.

With the arrangement so far described, the three electrode wires I2, I3and I4 as they are consumed are fed into the current discharge fusingzone of the flux II through the operation of the single motor 4I and atselective relative raies depending on the desired analysis cf the metalto be produced, this rate being determined by the sizes of thereplaceable gears Iila and SIb. Any variation in the speed of the motor4I will correspondingly vary the speed of feed of the electrode wiresI2. I3 and I4, but will not affect their relative rates of feed, so thatthe analysis of the metal being produced during any single castingoperation will remain substantially constant.

The motor 4I is controlled in accordance with the desired'rate of metalproduction and the desired characteristic of current discharge. 'I'hiscontrol-of the motor 4I can be effected from the current dischargecharacteristics of all the wires or may be effected from the currentdischarge characteristics of only one wire, as specifically shown. Tothat end, there is electrically connected across the generator 90 bymeans of wires 99 a control device or head 91 electrically conncted tothe motor 4I by wires 99 to regulate current to said motor from a supplysource 99. r'Ihe control head senses a specific characteristic of thecurrent discharge across the gap between the flux submerged end of theeelctrode wire I2 and the deposited molten metal 2l, and by regulatingthe speed of the motor 4I serves to maintain that characteristicsubstantially constant. The characteristic of the current discharge tobe sensed by the control head 91 is desirably the voltage across thecurrent discharge gap and for that purpose, this control head may be ofany suitable well-known type. For example, it may be of the so-calledUnionmelt" electronic type or of the Amplidyne motor-generator type, andis shown .provided with a handle |99 for manually setting the desiredvoltage across the current discharge gap, and a meter I9I indicatingsaid voltage. The voltage to which the control head 91 is set depends ona number of factors, as for example, on the desired rate of productionof the metal, the character of the electrode wires, and the desired rateof solidification of the metal deposited in the mold I9. Once thecontrol head 9.1 has been set to the desired condition, these will bemaintained automatically by the control of the speed of the motor 4 ISince the speed of the motor Il is controlled from the wire I2, thegenerators 9| and 92 must be set in any well-known manner to apredetermined relationship with respect to the generator Il, in drderthat the desired characteristics of the current discharge from theother-wires I3 and I4 are maintained, or if desired, the control head 91may be of a type and may be connected to sense the current dischargecharacteristics of all the electrode wires.

Also, if desired, instead of eifecting the control of electrode wirefeed automatically, as far as certain aspects of the invention areconcerned, this control may be effected manually by manually controllingthe speed of the motor to keep the voltage across the current dischargegap associated with any electrode wire at a selected point.

Also, as far as certain aspects of the invention are concerned, thespeed of the motor 4I may be kept constant, and the amperage to theelectrode wire or wires lvaried to maintain substantially constantconsumption or burn-off rate.

While the invention has been described with particular reference to aspecific embodiment, it is to be understood that it is not to be solimited thereto but is to be construed broadly and restricted solely bythe scope of the appended claims.

What is claimed is: -41

1. In an apparatus for producing metal by the fusing action of flux`submerged current discharges on consumable electrodes containing baseingredients of the metal to be .produced and for depositing the producedmetal in a mold below a blanket of flux, the combination comprising amotor, a pair of devices for feeding respective consumable electrodestowards the fusing zone in said blanket of flux as said electrodes areconsumed, and a pair o1' drive means between said motor and saidelectrode feeding devices respectively, for operating said feedingdevices simultaneously at predetermined relative rates, one of saiddrive means including a transmission changeable to alter its speed ratioselectively. whereby the relative rates of electrode feeds may bechanged selectively.

2. In an apparatus for producing metal by the fusing action of fluxsubmerged current discharges on consumable electrodes containing baseingredients of the metal to be produced and for depositing the producedmetal in a mold below a blanket of flux, the combination comprising amotor, a pair of devices forfeeding respective consumable electrodestowards the fusing zone in said blanket of flux as said electrodes areconsumed, and a pair of drive means between said motor and saidelectrode feeding devices respectively, for operating said feedingdevices simultaneously at predetermined relative rates, one of saiddrive means including a gear transmission having a gear and means forsupporting said gear in operative position, said gear being adapted tobe replaced by a gear of different size to change the speed ratio ofsaid transmission, and said gear supporting means being adjustable tosupport the replacing gear in operative position, whereby the relativerates of electrode feeds may be changed selectively.

3. In an apparatus for producing metal by fusing action of ux submergedcurrent discharges on consumable electrodes containing base ingredientsof the metal to be produced and for depositing the produced metal in amold below a blanket of flux, the combination comprising a motor, ashaft connected to said motor, a feed device for a consumable electrode,drive means between said shaft and said feed device adapted to drivesaid feed device, a second feed device for another consumable electrode,and a drive between said shaft and said second feed device comprising agear on said shaft, a second gear meshing therewith and a bearingbracket for 'said second gear. said second gear being replaceable by aSear of different size to change the speed ratio between said gears, andsaid bearing bracket being adjustable to bring the second gear intooperative mesh with said ilrst gear regardless of the size of saidsecond gear within a limited range, whereby the relative electrode feedsmay be changed selectively.

4. In an apparatus for producing metal by the fusing action of uxsubmerged current discharges on consumable electrodes containing baseingredients of the metal to be produced and for depositing the producedmetal in a mold below a blanket of ux, the combination comprising amotor, a pair of devices for feeding respective consumable electrodestowards the fusing z one in said blanket of flux as said electrodes areconsumed, and a pair of drive means between said motor and saidelectrode feeding devices respectively, for operating said feedingdevices simultaneously at predetermined relative rates. one of saiddrive means including a first shaft, a second shaft driven from said`first shaft, an adjustable bearing bracket for said first shaft, auniversal connection between said shafts permitting adjustments in theposition of said first shaft relative to said second shaft transverselyof their axes upon adjustment of said bearing bracket, while maintainingdrive connection between said shafts.

'and a transmission including a pair of inter- :sesam 1;

9 tive rates of electrode feeds may be changed selectively. y 5. In anapparatus for producing metal by the fusing action of flux submergedcurrent discharges from consumable electrode wires contain'- ing baseingredients of the metal to be produced and for depositing the producedmetal in a mold shaft and each of said additional feeding devices,

below a blanket of flux, the combination co'mprising means forsupporting a plurality of electrode wire reels or spools for free supplyrota-Y tion, a motor, a plurality of devlcesfor feeding the respectivewires from said reels towards the fusing zone `m said blanket of 'aux assaid elec- 'trode wires are consumed. and a Aplurality of drive meansbetween said motor and said electrode feeding devices respectively foroperating said feeding devices simultanemxsly @t Predeter- .minedrelative rates, each of said drive `means except one including atransmission cvxhangeable to alter its speed ratio selectively, wherebythe relative rates of electrode wire feeds may be changed selectively. Y

6. In an apparatus for producing metal by the fusing action of fluxsubmerged. current discharge and casting it in a mold adapted to containa layer of flux, comprising a platform disposed above said mold, meanson said platform for supporting a plurality of electrode wire reels forfree supply rotation above said mold. a motor on said platform, a deviceon said platform for feeding one of the wires from its corresponding vreel towards the fusing zone in said mold as said wire is consumed, adevice between said motor and said feeding device comprising a maindrive 'me of this patent: i

comprising a countershaft extending substantially parallel to said maindrive shaft, a drive gear on said main drive shaft, va. driven gearV ymeshing with -said drive gear, a shaft for said driven a bracket forlsaid latter gear shaft, anda universal connection between said gearshaft and said IcOunterShaIt, said driven gear being replaceable by agear of dinerent size to `alter the speed ratio between said gears, saidbearingl bracket being adjustable to permit replacement of said drivengear by another driven ygear o! different size into mesh with said gear,and said universal connection permitting the displacement of said gearshaft'with respect to said :countershaft resulting from change in saiddriven I '-fm-:FEnENoEsorrEp The following references are of record inthe UNITED STATES PATENTS Number Name Date 1,767,433 Hand Api'. 2, 19292,385,206 Hopkins Sept. 18, 1945 2,436,387

Harter et ai. A --,Peb. 24, 1948 nomazrvr-x norms. y

